Production of fluoroethylenes



3,043,889 PRODUCTION OF FLUQRUETHYLENES Lee B. Smith, Woodhridge, and Cyril Woolf, Morristown, N.J., assignors to Aliied Chemical Corporation, New York, N.Y., a corporation of New York N Drawing. Filed Mar. 22, 1960, Ser. No. 16,634 3 Claims. (Cl. 260-6535) This invention relates to manufacture of chlorotrifluoroethylene, CClF=CF Commercial production of chlorotrifluoroethylene is customarily effected by reduction of CCl FCCiF with zinc dust in the presence of alcohol. In view of 'the obvious cost disadvantages inherent in the metallic zinc procedure, several proposals have been made as to production of chlorotrifluoroethylene by catalytic reaction of CCl FCClF and hydrogen. In prior catalytic methods, various metals and metal compounds have been suggested as catalysts, and the reactors employed have been made of various metals such as nickel, stainless steel, iron and platinum. In some instances prior art catalysts have effected acceptable conversion and yields. However, catalyst longevity, a highly important factor in any gas-phase catalytic process, has been poor, and further some of the prior art catalysts which effect promising conversion and yields, in addition to being shortlived, are not readily amenable to regeneration. In the case of metal reaction vessels, at the fairly high temperatures needed to bring about good conversion and yields, the metal of metallic reaction vessels promotes fragmentation and carbonization. Moreover formation of halides, both chloride and fluoride, of the metal of the reactor has been pronounced and suflicient, more often than not, to plug up reactor outlet conduits with condensed halides and shorten operational runs some times as little as 4 to 6 hours.

The reaction involved in production of chlorotn'fluoroethylene by catalytic reaction of CCl FCClF and hydrogen is represented by This reaction inherently tends to form substantial amounts of by-products other than the sought-for CClF=CF Such by-products may be classified in two groupings: compounds such as CHF=F and CHClFCClF- which have not been defluorinated and are readily chlon'natable back to the CCI FCCIF starting material for recycling purposes; and compounds represented by CH =CF CH CF CHClF and CCl =CF which have been defluorinated or are otherwise not chlorinatable back to the CCI FCCIF starting material. While compounds of the first group may be chlorinated back to CCl FCC'lF such rechlorination requires a supplemental process step use of which should be reduced desirably to a minimum. More importantly by-products of the second group represent fluorine irrecoverably lost with respect to production of CClF=CF and to the extent of such loss overall process yield is correspondingly reduced.

A major object of this invention is to provide a process for making CC'lF- -CF by catalytic reaction of and hydrogen by procedure which effects high per pass yields, and remarkably high overall yields, i.e. high overall transformation of the CCl FCClF starting material to the sought-for CCIF CF This objective is accomplished by provision of the herein process which not only 'brings about high yields of CClF=CF per pass, butalso minimizes to a few percent the per pass formation of by-products of both the foregoing groups, that is those readily chlorinatable to CC-l F;CClF and those not chlo- I rinatable to CCI FCCIF 3,043,889 Patented July 10, 1962 According to the invention, it has been found that the foregoing objectives may be attained by carrying out the reaction in the presence of a certain catalyst and within a reactor having reaction-exposed surfaces made of certain refractory materials, and by careful control of reaction conditions with respect to temperature and mol ratios of CCl FCClF organic starting material to hydrogen.

The catalyst employed in practice of the invention is chromium oxide, Cr O which may be made into suitable catalyst form by any one of several known procedures. -The chromium oxide may be utilized in supported or unsupported condition, unsupported as chromium oxide pellets, or supported on refractory material e.g. silica, alumina, or Alundum chips, or calcium or magnesium fluoride. If chromium oxide in pelletized form is desired, chromium hydroxide may be precipitated for example from a solution of 530 g. of Cr(N-O 9H O in 2000 ml. of water by adding, with agitation, 500 g. of 28% NH OH, and heating to about C The precipitated hydroxide may be separated from the solution by filtration, dried at temperature of about 125 C., and suitably pelletized to form pellets of e.g. 4; dia. x /8" long. Chromium oxide catalyst in supported form may be prepared by soaking Alundum chips, e.g.: 4-8 mesh, in a saturated solution of chromium nitrate, filtering, drying, and heating attemperature of about 200 C. for about 3 hours to convert the nitrate to the oxide. Alternatively, supported chromium oxide catalyst may be made by coprecipitating chromium hydroxide and a refractory material such as calcium or magnesium fluoride, and after filtering and washing, heating the filter cake to convert the hydroxide of chromium to the oxide. Following is a specific example for making a supported chromium oxide catalyst suitable for use in practice of the invention. 173 g. Mg(NO 61-1 0 and 147 g. Cr(NO 9H O are dissolved in 1400 ml. of water. To this, while agitating, is added a solution of 79 g. KF' and 62 g. KOH in 800 ml. of water. The mixture is boiled, filtered, washed, the cake driedat C., and granulated to e.g. 6-14 mesh size. In the case of unsupported catalysts, the latter consist of Cr O in granule or pellet form of say /8" dia. x long, and in the case; of supported catalysts, such catalysts consist of Cr O and the refractory inert supporting material, and may contain by weight from one or more percent up to about 60%, preferably 2.5 to 45% of Cr O It has been found, as herein demonstrated, that under the described conditions of reaction these catalysts are highly active as to CClF=CF formation minimize fragmentation and carbonization and formation of all types of byproducts, and are notably long-lived. Regeneration is simple when needed, and may be effected by discontinuing the feed of organic and hydrogen, purging with nitrogen, and then feeding air or oxygen for about 2 hours without changing the reactor temperature.

A second important factor in practice of the invention lies in the materials which comprise the reactor surfaces exposed to reaction conditions. In accordance withthe invention, these surfaces are made of non-metallic refractory oxide material of the group consisting of Alundum, porcelain, fused silica and zirconia. These materials minimize carbonization and fouling of catalyst, and substantially eliminate in the reaction zone the presence of metal halides which are characteristic of the prior art catalytic methods of the type under discussion. Metal halides adversely affect catalyst longevity, enhance deterioration of metallic reactors themselves, and most disadvantageously result in plugging up of the gas, conduit between the outlet of the reactor and the recovery system with condensed metal halides.

to be rechlorinated to CCl FCClF Temperatures employed in practice of the invention fall within a relatively narrow range. Some reaction takes hold at temperatures of about 475 C. However, Worthwhile minimum reaction zone temperature of about 485 C. is preferred. As to'maximum temperature, in order to obtain the high per pass and high overall yields hereinafter demonstrated, temperatures should not exceed about 550 C., preferred temperature being substantially in the range of 500- 50 C. Practicein this temperature range avoids fragmentation, carbonization, minimizes formation of by-products of both types, and particularly byproducts not chlorinatable to CCI FCCIF A process control factor of major importance is the mol ratios of the CCl FCClF organic starting material to hydrogen in the vapor phase mixture of incoming reactants charged into the reaction zone. Herein the term conversion denotes mol percent of organic starting material consumed. Investigations show that, in order to effect attainment of the demonstrated yields, the reaction should be carried out in such a way, with regard to temperature, mol ratios of incoming reactants and contact time, as to effect relatively low conversions per pass.

In practice, it is desirable to adjust proportions of the incoming 'CCl FCCl'F and hydrogen reactants so as to bring about conversion per pass in the range of about 15-30%, preferably 2030%. This objective is accomplished by supplying to the reaction zone a vapor-phase mixture of CCl FCClF and hydrogen in mol ratio of not less than 1.25 mol of CCl FCClF per mol. of hydrogen. In the interest of consistently good results, it is preferred to employ reactant feed in amounts not substantially less than 2 mol proportions of CCl FCClF per mol of hydrogen. It has been found that a greater proportion of hydrogen sharply decreases per pass yield of CCIF CF and notably increases formation of by-products not chlorinatable to CCl FCClF Maximum proportion of CCl FCClF in the reactor feed is not particularly critical although no'advantages are obtained by use of more than about 4 mols of CClzFCClFz per mol of hydrogen. In

. best operation, the vapor-phase mixture fed to the reactor contains CCl FCClF and hydrogen in mol proportions of substantially 2, to 3 mols of CCl FCClF per mol of hydrogen. Contact time may vary in the range of about 2-25 seconds, preferably 2-l5 seconds, and may be chosen and co-ordinated with temperature and mol ratios by a test run or two.

Handling and recovery of materials exiting the reaction zone may be substantially as conventional in this art. For example, the reactor zone exit may be waterscrubbed to remove HCl and any HF and possibly condense and collect some'of the relatively high boiling CCI FCCIF The vaporous exit of the scrubber may be dried as by a calcium chloride tower, the exit of which may be totally condensed in Dry Ice and liquid nitrogen col-d traps connected in series. The condensates from the cold traps maybe combined with any high boiling organic condensate collected in the Water scrubber, and may then be distilled in the usual way. By-products chlorinatable to CCl FCClF may be so chlorinated as known in the art and recycled along with unreacted CC1 FCClF As will be seen, from the following examples, in the better embodiments of the invention, yields of CClF=CF per pass are high, i.e. in the general range of- 70-80%. Starting material losses to by-products not chlorinatable to CClgFCClF are around 2%, and such losses combined with mechanical'lossesare less than 5%. Further, transformation per pass of starting material to by-products chlorinatable to CCl FCClF is of the order of 3% and gloss, thus reducing to a minimum the amount of material By recycling unreacted CCl FCClF and by-products chlorinatable to ccnncoln overall yields of starting material to CClF=CF are well upwardsof 90% and usually better than 95%.. Further, catalyst longevity is notable as is shownby the examples. In runs similar to those given aoaaeae in the examples, and using Cr O supported on Alundum chips, the catalyst was used for about 53 hours before regeneration, and thereafter for about 155 hours with no significant activity decline. 0

In the following examples conversion indicates mol percent of organic starting materials consumed, and yield indicates mol percent of starting material consumed which was transformed to sought-for product, i.e. CClF=CF Percentages noted are mol percent unless otherwise indicated.

Example 1.The reactor employed was an Alundum tube of 1 LD. and 36" long mounted in an electrically heated furnace which enveloped approximately the central 30" length of the tube. The central 13" length of the reactor contained about 168 ml. of catalyst which consisted of chromium oxide on Alundum chips prepared, as previously described, by soaking Alundum chips, 4 x 8 mesh, in a saturated solution of chromium nitrate, drying,

and heating to convert the nitrate to the oxide. The catalyst contained about 3% by weight of chromium oxide, Cr O Over a period of about 5 hrs., there were passed into the reactor about 3.12 mols of vaporized CCl FCClF and about 1.5 mols of hydrogen. Mol ratio of organic starting material to hydrogen was about 2:1. Temperature in theheated section of the reactor was maintained at about 525 C. throughout the run. Rate of feed of reactants was such that retention time of reactants in the reactor was about 10 seconds. Reactor exit material handling and recovery was as previously described, i.e. substantially as conventional in this art. On final distillation of the combined condensates from the Dry-Ice and liquid nitrogen cold traps combined with the high boiling organic condensate collected in the water scrubber there were obtained 0.0106 mol CHF CF B.P. minus 62 C.; 0.0254 mol of material collectively including CH =CF CH CF and CHClF having respective boiling points of minus 83 0, minus 47.3 C, and minus 40.8 C.; 0.56 mol CClF=CF B.P. minus 26.8 C.; 0.03 mol CCI CF Bl. 18.9" C.; 0.091 mol CHClFCClFg, B.P. 28 C.; and 2.35 mols CCl FCClF B.P. 47.7 C. Organic material recovery amounted to about 97.5% of the CCI FCClF fed. Conversion per pass was about 24.5%, and yield of CClF=CP per pass was about 73%. Loss of starting material to by-products not chlorinatable to CCI FCCIF and represented by CH CE CH CF CHClF and CCl =CF was only about 1.8%. Further, transformation of organic starting material to CHF CF and CHClFCClF which are byproducts readily chlorinatable to CCl FCClF was only about 2.3%. As to organic starting material, mechanical loss plus loss to by-products not chlorinatable to the CCl FCClF amounted to only about 4.3% per pass. Thus, by recycling unreacted CCl FCClF and by-products chlorinatable to CCl FCClF overall transformation of organic starting material to CClF -CF is better than .Up to the end of this, run the catalyst had been in use in similar runs for about 52.5 hours without regeneration.

Example 2.Apparatus and catalyst employed were as in Example 1. Over a period of about 5 hrs., there were passed into the reactor about 2.78' mols of vaporized CCl FCClF and about 1.5 mols of hydrogen. Mol ratio of organic starting material to hydrogen was'about 2:1. Temperature in the heated section of the reactor was maintained at about 525 C. throughout the run. Rate of feed of reactants was such v that retention. time of reactants in the reactor was, about 10 seconds. Reactor exit material handlingand recovery was as in Example 1. On final distillation of the combined condensates from the Dry-Ice and liquid nitrogen cold traps combined with the high boiling organic condensate collected in the water scrubber there were obtained 0.02 mol of material collectively including CH =CF CH CF and CHClF 0.009 mol CHF=CF 0.51 mol CClF==CF 0.03 mol CCl =CF 0.06 mol CHClFCC1F and 2.14 mols CCI -FCCIF Organic material recovery amounted to about 99.5% of the FCl FCClF fed. Conversion per pass was about 23%, and yield of CClF:OF per pass was about 80%. Loss of starting material to by-products not chlorinatable to CCI FCCIF and represented by CH CF CH CF CHClF and CCI CF was only about 1.8%. Further, transformation of organic starting material to CHF=CF and CHCIFCCIF which are byproducts readily chlorinatable to CCI FCCIF was only about 2.5%. As to organic starting material, mechanical loss plus loss to by-products not chlorinatable to the CCl FCClF amounted to only about 2.2% per pass. Thus, by recycling unreacted CCI FCCIF and by-products chlorinatable to (301 1 0011 over-all transformation of organic starting material to CClF=CF is better than 97%.

Example 3.--The reactor employed was an Alundum tube of LD. and 36" long mounted in an electrically heated furnace which enveloped approximately the central 30" length of the tube. The central 14" length of the reactor contained about 70 ml. of catalyst which consisted of chromium oxide prepared, as previously described, by coprecipitating chromium hydroxide and magnesium fluoride, filtering, washing, drying, granulating to 6 x 14 mesh, and heating to convert the hydroxide of chromium to the oxide. The catalyst contained 40% by weight of chromium oxide Cr O balance, magnesium fluoride acting as a support. Over a period of about 5 hrs., there were passed into the reactor about 2.16 mols of vaporized CCl FCCIF and about 2.25 mols of hydrogen. Mol ratio of organic starting material to hydrogen was about 1:1. Temperature in the heated section of the reactor was maintained at about 525 C. throughout the run. Rate of feed of reactants was such that re-' tention time of reactants in the reactor was about 4 seconds. Reactor exit material handling and recovery was as previously described, i.e. substantially as conventional in this art. On final distillation of the combined con densates from the Dry-Ice and liquid nitrogen cold traps combined with the high boiling organic condensate collected in the water scrubber there were obtained 0.179 mol of material collectively including CH =CF CH CF and CHCIF 0.071 mol CHF CF 0.466 mol CClF=CF 0.008 mol CC1 =CF 0.022 mol CHClFCClF and 1.353 mols CCl FCClF Organic material recovery amounted to about 97.3% of the CC1 FCClF fed. Conversion per pass was about 37%, and yield of CClF=CF was about 51%. Loss of starting material to by-products not chlorinatable to CCl- FCClF and represented by CH CF CH CF CHClF and CCI CF was about 8.6%. Further, transformation of organic starting material to CHF=CF and CHCIFCCIF which are by-products readily chlorinatable to CCl FCCIF was only about 4.3%. As to organic starting material, mechanical loss plus loss to by-products not chlorinatable to the CCI FCCIF amounted to about 11.3% per pass. By recycling unreacted CCl FCClF and by-products chlori natable to CCl FCClF overall transformation of organic starting material to CCIF CF is better than 88%. Up to the end of this run the catalyst had been in use in similar runs for about 30 hrs. without regeneration and without indication of activity decline. This run demonstrates criticality of mol ratio of organic starting material to hydrogen in the reactor feed. With low ratio, while conversion is higher, yield per pass of CCIF=CF is notably lower, and loss to by-products not chlorinatable to CCl PCClFg is substantially increased.

We claim:

1. The process for making CClF=CF which comprises charging into a reaction zone a vapor-phase mixture of CCl FCClF and hydrogen in mol proportions of not less than 1.25 mols of CCl FCCI'F per mol of hydrogen, subjecting said mixture to heating in said zone to temperatures substantially in the range of 475-550 C. while in the presence of a catalyst consisting of chromium oxide and for contact time substantially in the range of 2-15 seconds to effect per pass conversion of CCl FCClF substantially in the range 15-30%, said reaction zone being defined by solid surfaces of non-metallic refractory oxide material of the group consisting of Alundum, porcelain, fused silica and Zirconia, and recovering CClF=CF from the materials exiting the reaction zone.

2. The process of claim 1 in which the said vaporphase mixture contains CCI FCCIF and hydrogen in mol proportions of not substantially less than 2 mols of CCl FCClF per mol of hydrogen.

3. The process for making CCIF==OF which comprises charging into a reaction zone a vapor-phase mixture of CCl FCClF and hydrogen in mol proportions of substantially 2-3 mols of CCl FCClF per mol of hydrogen, subjecting said mixture to heating in said zone to temperatures substantially in the range of SOD-550 C. while in the presence of a catalyst consisting of chromium oxide and for contact time substantially in the range of 2-15 seconds to effect per pass conversion of CCI FCCIF substantially in the range 15-30%, said reaction zone being defined by solid Alundum surfaces, and recovering CCIF=CF from the materials exiting the reaction zone.

Mantell Dec. 14, 1954 Miller et a1. Dec. 16, 1958 

1. THE PROCESS FOR MAKING CCIF=CF2 WHICH COMPRISES CHARGING INTO A REACTAION ZONE A VAPOR-PHASE MIXTURE OF CCL2FCCLF2 AND HYDROGEN IN MOL PROPORTIONS OF NOT LESS THAN 1.25 MOLS OF CCL2FCCLF2 PER MOL OF HYDROGEN, SUBJECTING SAID MIXTURE TO HEATING IN SAID ZONE TO TEMPERATURES SUBSTANTIALLY IN THE RANGE OF 475-550*C. WHILE IN THE PRESENCE OF A CATALYST CONSISTING OF CHROMIUM OXIDE AND FOR CONTACT TIME SUBSTANTIALLY IN THE RANGE OF 2-15 SECONDS TO EFFECT PER PASS CONVERSION OF CCL2FCCLF2 SUBSTANTIALLY IN THE RANGE 15-30%, SAID REACTION ZONE BEING DEFINED BY SOLID SURFACES OF NON-METALLIC REFRACTORY OXIDE MATERIAL OF THE GROUP CONSISTING OF ALUNDUM, PORCELAIN, FUSED SILICA AND ZIRCONIA, AND RECOVERING CCLF=CF2 FROM THE MATERIALS EXITING THE REACTION ZONE. 